Title of Invention	"A FLY ASH BASED COMPOSITION USEFUL FOR MAKING WOOD SUBSTITUTE AND A PROCESS FOR THE PREPARATION THEREOF"
Abstract	The present invention provides a fly ash based composition useful for making wood substitute comprising fibre in the range of 0.5-5% by wt., fly ash in the range of 20-65 wt. %, thermosetting resin 30-40% by wt., diluents 5-50 wt % and additive 0-0.5wt %. The present invention also provides a process for the preparation of above said composition useful for making wood substitute.

Full Text

The present invention relates to a fly ash based composition useful for making wood substitute. The present invention particularly relates to a novel composition comprising of fly ash, natural fibre and polyurethane resin for making wood substitute therefrom. All over the world, thermal power plants produce large amount of fly ash .It is necessary to convert this waste in to a valuable product .A novel composition comprising of fly ash, fibre and polyurethane resin has been prepared, which can be used for making door shutters as wood substitute, partitions corrugated roofing and for insulation applications. Fly ash creates pollution in and around the dumping sites. Several researches have been done to utilise this waste as filler in cements and for making bricks. The reference can be made to U.S. Patents 5,047,145, 5,227,047 and 6,027,551 by Institute of Materials Processing at Michigan Technological University, Houghton, Michigan wherein a mineral called Basanite (CaSO4) is removed from the surface of the fly ash. Basanite is a gypsum-like material that has a retarding effect on cement in concrete mixtures. Froth flotation process is used to remove carbon and enhance the fly ash. The removal via wet processing improves early set and strength in concrete. This process produces a consistent enhanced pozzolan product. Carbon content of 1.0% or less has no effect on entrained air in concrete. The reference can be made to patent application No.Hl 1-51745 wherein a method for producing composition by using coal ash, and heavy weight aggregate as remedy for its weight deficiency, yielding a hardened material, which can substitute for all kinds of concrete blocks is proposed. Vibration acceleration of 3G or greater is used for compacting to produce the solid. Reference may be made to September 3, 1998 announcement of First Energy Corporation (NYSE:FE), Crown Coal & Coke Company and Canyon Resources, Inc. ,wherein the formation of Carbon Plus. Carbon Plus process separates coal from fly ash, creating high grade carbon and low carbon fly ash, products are utilized in the steel, foundry and cement industries. Reference may be made to Toyaki Miyagawa, Susumu Inoue's paper in Cement and Concrete Composites (2000) 22,1pp. v-v. wherein the attempts have been done of mixing fly ash with concrete. Reference may be made to the paper by Zouheir A. Hashem, Robert L. Yuan, Construction and Building Materials 2001,15,8, pp. 369-378 wherein short vs. long column behavior of pultruded glass-fiber reinforced polymer composites has been reported for construction, The drawbacks are that the above patents and papers are related to use of fly ash mixed concrete and cement in construction .Similarly pultruded glass-fiber reinforced polymer composites are used in construction. No report is available on the composition comprising of fly ash, fibre and polyurethane resin composition for application in wood substitution or in insulation, which needs desired density comparable to wood or insulation panel. The main object of the present invention is to provide a novel composition comprising of the fly ash, fibre and polyurethane resin for making wood substitute there from, which obviates the drawbacks as detailed above. Another object of the invention is to provide a process for making a new type of wood substitute composition for insulation, which needs desired density comparable to wood or insulation panel. Accordingly the present invention provides a fly ash based composition useful for making wood substitute comprising fibre in the range of 0.5-5% by wt., fly ash in the range of 20-65 wt. %, thermosetting resin in the range of 30-40% by wt., diluents in the range of 5-50 wt %, additive in the range of 0-0.5wt % and the said composition has the following characteristics: compression strength is in the range of 19-120 kg/cm2, density is in the range of 0.7-0.8 g/cm3 and colour of the composition is grey. In an embodiment of the present invention the thermosetting resin used is of commercial grade room temperature fomable two component polyurethane resin system. In yet another embodiment the commercially available two component polyurethane resin is having foaming density ranging from 12 pcf to 50 pcf. In yet another embodiment the additive used is Ti02 or any other fibre retardant in less than 0.5 wt %. In yet another embodiment the fibre used is selected from the group consisting of Jute, Sun hemp, Minwool fibre, Polyester, Nylon and Sisal having length ranging from 15µm to 5 mm. In yet another embodiment the diluent used is selected from the group consisting of ethylene carbonate, propylene carbonate and acetone. The present invention further provides a process for the preparation of a composition useful for making wood substitute which comprises drying fly ash and fibers, at a temperature in the range of 50-80°C, for a period of 45-60 minutes, mixing the above said dried fiber in the range of 0.5-5% by wt, dried fly ash in the range of 20-65 wt. %, additive 0-0.5wt %, polyurethane resin 30-40% by wt., diluents 5-50 wt % and pouring the above said ingredients mixture to a desired shaped mould, followed by curing, at a temperature in the range of 70-90°C, for a period of 3-10 hrs to make the desired component. In an embodiment of the present invention the heat treatment to ingredients mixture for curing with mould is done preferably at a temperature in the range of 60-80°C. The following examples are given by way of illustration and therefore should not be construed to limit the scope of the present invention. Example 1 Following ingredients were taken Ingredients 1. Jute fibre (length 2mm).+wood flour (0.75+0.25) wt% 2. Fly ash (60.0 wt%) 3. Polyurethane resin (Part A + Part B) (39.0 wt%) 4. Acetone 10wt% of resin Process All the above ingredients were dried in an oven for 1 hr at 60°C except polyurethane resin components. Part A and Part B of the commercial grade rigid polyurethane resin from Expanded incorporation Mumbai were separately diluted with % 5 phr acetone/or by any other polar solvent such as Ethylene/propylene carbonate. Separately 50 -50 % of the mix of the fly ash filler along with fibre and additives were added seperately to part A and Part B and stirred thoroughly at 20 rpm for 2 minutes. After this ,mix A and B were mixed and stirred at 20 rpm for 30 to 60 second then thefinal mix was transferred to a desired cavity mould at room temperature and covered with lid or pressed at 0.5 - 5 kg/cm2 pressure in a compression moulding machine for 15 to 20 mins. Then the sample with mould was transferred to a hot oven for 3. hrs. The temperature of oven was kept 80°C for postcurring. After this composite sample was removed at room temperature. The sample was trimmed to the desired size. Properties of the sample such as density was 0.78 g/cm3. The colour of sample was grey. 1. Compressive strength is 120.0 kg/cm2. Example 2 Following ingredients were taken Ingredients 5. jute fibre (length 2mm.) BHEL provided the critical design inputs, RRL provided the technology and permali Wallace acted as a manufacturing partner (1.0wt%) 6. Fly ash (62.0 wt%) 7. Polyurethane resin resin (Part A + Part B) (37.0 wt%) 8. Acetone 10wt% of resin Process All the above ingredients were dried in an oven for 1 hr at 60°C except polyurethane resin resin components. Part A and Part B of the commercial polyurethane resin were separately diluted with % 5 phr acetone/or by any other polar solvent such as Ethylene/propylne carbonate. Separately 50 -50 % of the mix of the fly ash filler along with fibre and additives were added separately to part A and Part B and stirred thoroughly at 20 rpm for 2 minutes. After this ,mix A and B were mixed and stirred at 20 rpm for 30 to 60 second then the final mix was transferred to a desired cavity mould at room temperature and covered with lid or pressed at 0.5 - 5 kg/cm2 pressure in a compression moulding machine for 15 to 20 mins. Then the sample with mould was transferred to a hot oven for 3.1 hrs. The temperature of oven was kept 80°C for post curing. After this composite sample was removed at room temperature. The sample was trimmed to the desired size. Properties of the sample such as density was 0.7 g/cm3. The colour of sample was grey. The following results were obtained Compressive strength 19.6 kg/sq cm Example 3 Following ingredients were taken Ingredients 1. Jute fibre (length 2mm.) (1.0wt%) 2. Fly ash (64.0 wt%) 3. Polyurethane resin resin (Part A + Part B) (35.0 wt%) 4. Dilutent 50ml 5. Acetone 10wt% of resin Process The fly ash and were weighed and dried All the above ingredients were dried in oven for 1 hr at 60°C except polyurethane resin resin components. All the above ingredients were dried in an oven for 1 hr at 60°C except polyurethane resin resin components. Part A and Part B of the commercial polyurethane resin were separately diluted with % 5 phr acetone/or by any other polar solvent such as Ethylene carbonate or propylene carbonate . Separately 50 -50 % of the mix of the fly ash filler along with fibre and additives were added seperately to part A and Part B and stirred thoroughly at 20 rpm for 2 minutes. After this ,mix A and B were mixed and stirred at 20 rpm for 30 to 60 second then thefinal mix was transferred to a desired cavity mould at room temperature and covered with lid or pressed at 0.5 - 5 kg/cm2 pressure in a compression moulding machine for 15 to 20 mins. Then the sample with mould was transferred to a hot oven for 3.2 hrs. The temperature of oven was kept 80°C for postcurring. After this composite sample was removed at room temperature. The sample was trimmed to the desired size. Properties of the sample such as density was 0.7 g/cm3. The colour of sample was grey. Compressive strength 19.3kg/sqcm Advantages The main advantages of the present invention are: 1 This composition utilizes the fly ash in large percentage. 2. This invention provides a new composition comprising of using fly ash ,natural lingo cellulosic fibre and rigid polyurethane resin, a resin solvent 3. Density of the material ranges from 0.3 to l.Ogm/cc 4. Composition is eco friendly 5. This composition is economical 6. Composition is useful for making partitions, door panels and insulation panels We Claim 1. A fly ash based composition useful for making wood substitute comprising fibre in the range of 0.5-5% by wt., fly ash in the range of 20-65 wt. %, thermosetting resin 30-40% by wt., diluents in the range of 5-50 wt %, additive in the range of 0-0.5wt % and the said composition has the following characteristics: a) compression strength is in the range of 19-120 kg/cm2, b) density is in the range of 0.7-0.8 g/cm3 and c) colour of the composition is grey. 2. A composition as clamed in claim 1 where in the thermosetting resin used is of commercial grade room temperature fomable two component polyurethane resin system. 3. A composition as claimed in claim 1&2 wherein the commercially available two component polyurethane resin is having foaming density ranging from 12 pcf to 50 pcf. 4. A composition as claimed in claim 1-3 wherein the additive used is TiO2 or any other fibre retardant in less than 0.5 wt %. 5. A composition as claimed in claim 1-4 wherein the fibre used is selected from the group consisting of Jute, Sun hemp, Minwool fibre or Polyester or Nylon or Sisal having length 15|* to 5 mm. 6. A composition as claimed in claim 1-5 wherein the diluent used is selected from the group consisting of ethylene carbonate, propylene carbonate and acetone. 7. A process for the preparation of a composition as claimed in claim 1 useful for making wood substitute which comprises drying of fly ash and fibers at a temperature in the range of 50-80°C for a period in the range of 45-60 minutes, mixing the above said dried fiber in the range of 0.5-5% by wt., dried fly ash in the range of 20-65 wt. %, additive 0-0.5wt %, polyurethane resin 30-40% by wt., diluents 5-50 wt % and pouring the above said ingredients mixture to a desired shaped mould, followed by curing, at a temperature in the range of 70-90°C, for a period of 3-10 hrs to make the desired component. 8. A fly ash based composition useful for making wood substitute substantially as herein described with reference to the examples accompanying this specification.

Documents:

253-DEL-2003-Abstract-(07-07-2008).pdf

253-DEL-2003-Claims-(07-07-2008).pdf

253-DEL-2003-Claims-(14-07-2008).pdf

253-DEL-2003-Correspondence-Others-(07-07-2008).pdf

253-DEL-2003-Correspondence-Others-(14-07-2008).pdf

253-DEL-2003-Form-1-(07-07-2008).pdf

253-DEL-2003-Form-1-(14-07-2008).pdf

253-del-2003-form-18-(07-07-2008).pdf

253-DEL-2003-Form-2-(07-07-2008).pdf

253-DEL-2003-Form-3-(07-07-2008).pdf

253-DEL-2003-PA-(14-07-2008).pdf

253-del2003-abstract.pdf

253-del2003-claims.pdf

253-del2003-correspondence-others.pdf

253-del2003-correspondence-po.pdf

253-del2003-description (complete)-07-07-2008.pdf

253-del2003-description (complete)-14-07-2008.pdf

253-del2003-description (complete).pdf

253-del2003-form-1.pdf

253-del2003-form-18.pdf

253-del2003-form-2.pdf

253-del2003-form-3.pdf